SPIRAL BEVEL GEAR HOBBING MACHINE THB 600 CNC

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1 SPIRAL BEVEL GEAR HOBBING MACHINE THB 600 CNC

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3 1. The characteristics of the machine 2. Overview Introduction of the Machine s Overall Structure, Function, and Control etc. THB 600 CNC is spiral bevel gear milling machine with six CNC axes. This is milling machine of high stiffness high precision and high efficiency to machining Gleason tapered tooth-spiral bevel and hypoid gear. Under the condition of environment temperature between +5 to +36 the THB 600 CNC milling machine is capable to reach class 6 accuracy according to DIN 3965 spiral bevel and hypoid gear accuracy standard. Tooth flank roughness maximum Ra Usage of the Machine The machine not only can mill those zero bevel gears, spiral bevel gears, and hypoid gears that are processed through Gleason methods, but also can process Oerlikon spiral bevel gears by installing a 1: 4 cutter head holder at the cutter s main axis, where the Oerlikon cutter head can be installed. Machine model THB 600 CNC works all the methods (Verfaren) according to the table no.1. TOS-013-US

4 Gleason methods TOS-013-US

5 Oerlikon - KLINELNBERG methods As we know, spiral bevel gear is the critical part that is widely used in such machines as automobile, tractor, construction machinery, electric tool, and industrial sewing machine etc., and thus its quality is closely associated with these machines performance. To improve the spiral bevel gear s quality, we should not only improve its materials, but also adopt advanced process method and sophisticated process equipment. At present, we employ the advanced six-axis and five-linkage CNC spiral bevel gear milling machine to displace the outdated gear milling machine to improve the precision, which is both a necessary and a practical process measure. Due to this, spiral bevel gear vendors take the six-axis and five-linkage CNC spiral bevel gear milling machine as one of their core equipments, so as to improve their product quality (namely, to improve the precision and reduce the surface roughness). The mechanical-type gear milling machine, which is used in machining the spiral bevel gear, is of complicated structure, numerous adjustment links, and complicated operations. Moreover, its quality is directly associated with the machine s production efficiency and machining quality. In the beginning of 1990s, US-based GLEASON was the first company that successfully developed the CNC six-axis and fivelinkage spiral bevel gear milling machine. Compared to mechanical-type gear milling machine, the CNC spiral bevel gear milling machine is free from the mechanical adjustment links, and takes advantage of the computer to realize the five-axis linkage and complete the entire milling process. Therefore, the machine has a series of strong points like simple structure, good rigidity, short drive chain, no mechanical linkage, high precision, highly flexible program control, simple adjustment, and high efficiency etc. In a manner of speaking, CNC spiral bevel gear milling machine represents the gear milling machine industry s development orientation because it simplifies the hardware configuration by software, and upgrades the spiral bevel gear s automatic production to the informatized production. Besides TOS Hostivař, only USbased GLEASON and Germany-based KLINELNBERG have the ability to produce this product, but the prices of imported products are extremely high Software Attached with Machine Producing SW: 1) Flexibility controlling system 2) Different producing SW 3) Different electrical controlling SW 4) Online testing 5) Automatic margin distributor TOS-013-US

6 Computer SW: 1) gear designing SW 2) hardness calculation. Fatigue calculation 3) moving deviation SW 4) TCA analysis SW Software of spiral bevel gear design analyze and machining calculation, spiral bevel and hypoid gear design machining software and tooth contact analyze (TCA)program. 5) LTCA analysis SW 6) Testing Opposition SW 2.3. Machine Standard Equipment 1. Work-area guarding. 2. Automatic centralize lubrication system and hydraulic system. 3. Hydraulic workpiece chucking. 4. Air-conditioned integrated electrical cabinet with net cable, CNC numerical control equipment and integrated PLC. 5. Machine control panel with display and electrical hand wheel. Switch for workpieces clamp and unclamp. 6. Germany REXROTH or Japan THK rolling guide and NSK ball screw, linear axes and revolving spindle adopt Germany Heidenhain high resolution linear and rotary encoders. 7. SIEMENS spindle motor and servo AC motors Machine Body and All Coordinate Axes Configuration X cutter main axis s horizontal direction: forward, backward Y cutter main axis s vertical direction: upward, downward Z Saddle direction: forward, backward A Work piece main axis rotary motion B wheel blank mounting angle s rotary motion C cutter main axis s rotary motion Components TOS-013-US

7 3. Briefings of the Machine s Strong Points and Advantages THB 600 CNC gear milling machine s major strong points and advantages include: Cutter main axis (C-axis) adopts Siemens main axis motor and precise backlash gearbox drive The work piece main axis (A-axis) adopts large-torque embedded moment motor drive X, Y, and Z-axis adopt the direct drive mechanism The machine is equipped with the automatic stock dividing device, and it can be upgraded to the online measurement A, B, X, Y, and Z-axis belong to closed-loop control Major parts of the machine are analyzed and calculated according to the finite element theory All bearings, servo motors, lead screws, guide rails, CNC systems, and measurement elements are international renowned brands All auxiliary devices are domestic renowned brands The machine is of high rigidity, high intensity, high speed, and high precision. The machine can process the all-round machine tools through constant generating cutting method and face milling method. 4. Technical parameters Bevel Gear Hobbing Machine THB 600 CNC Machine CNC system and Software: CNC system Display Servo drive System Electrical Hand Wheel TOS-013-US SIEMENS 840 D sl, 6 axes 15 TFT SIEMENS Digital AC Motor Siemens System Form a CompleteSet Electrical Hand Wheel Software attached with the Machine: SW Bevel Gear Milling Machining SW Spiral Bevel Gear Design analyze and machining calculate spiral and hypoid gears, machining software and tooth contact analyze TCA program Parameter unit. Value 1 Machined part Max. transmission ratio 1 10:1 Max. module mm 13 Tooth number Max. pitch circle diameter. mm 600 Max. tooth face wide mm 110 Range of midpoint spiral angle Range of milling cutter head, inch 7, Instalation of milling cutter head centering: mm -for taper 1:24 -for taper 1:2 58, ,966 4 Work Lager end diameter mm spindle Taper 1 1 : 16 Taper hole depth mm 160 Diameter of through hole mm 120 Depth of through hole mm Transmissi Lager-end diameter mm 99,2187

8 on bushing Taper 1 1 : 19,6923 taper hole Taper hole depth mm Work spindle revolution rpm Milling cutter head depth rpm Machine total power kw 60 Input power requirement Voltage 380V ±10% Frequency 50Hz Power drop out 10 µs Total connected load 80 kva Compressed air quality Pressure 0,6 МРа Flow rate max. 0,4 m3/min Humidity condensation point max. 3 C Temperature 5-36 Milling oil Amount 1000 l Viscosity ISO-VG Recommended brand and trademark BLASO MILL 22 Ruishibasuo Lubricating oil Amount 30 l Recommended brand and trademark Mobil Vactra Oil 4 Hydraulic oil Amount 200 l Recommended brand and trademark Mobil DTE 25 Environment Indoor сухое Temperature indoor 5 C - 36 C Max. air humidity 75% Installation parameters Space dimension L x W x H 3840 х 2525 х 2930 mm Weight kg 5. Briefings of the Structure - Brief Introduction of Major Systems 5.1 Machine Body The machine body is the supporting component of the machine, and at the top left part of the machine body there are such components as X slide rest, column, Y-axis drive device, and milling main spindle box etc. At the right end there are parts like Z-axis slipway, rotary table, work piece, and main axis box etc. At the left lower part there is a magnetic scrap removal device. As a box-type cast part, the machine body is equipped with a channel for the magnetic scrap removal device in its machining zone, and at the rear end of the body the machine is connected with an oil tank. During the machining process, oil from the cooling pump will flow through the pipeline to the milling main spindle box s machining zone at the machine so as to cool the work piece and cutters. After that, the oil, together with the chips, will flow into the machine body and then it will be discharged into the chip dumping vehicle near the oil tank through magnetic scrap removal device in the body channel. On the oil tank there is a cooling pump, which will send the oil that flows back into the oil tank into the machining zone again. TOS-013-US

9 5.2 X-axis Slide Rest X axis slide rest, which is installed at the left end of the machine body, serves as the base for milling main spindle box to move horizontally along X direction. On the slide rest there are two Rexroth column roller guide rails for linear motion, and the two guide rails slide block and column are fixed. To reduce the drive chain s error, X axis adopts AC servo motor direct drive ball bearing lead screw for rotary motion, so as to make the machine s column and those parts like milling main spindle box on the column to move horizontally along X direction. At both ends of the slide rest there are limit switches that limit the moving distance and mechanical iron blocks that can prevent the column from going beyond the position. On one side of the slide rest there is one straight line coding ruler, which is used to feed back the milling main axis center s actual position along the X direction. 5.3 Column The column, a gantry-type cast part, is a basic part that is installed at milling main spindle box and Y-axis drive device. Also, it serves as the supporting component to protect the machine. On both sides of the column s frontal face there are Rexroth straight-line rolling guide rails, whose slide blocks are connected with the milling main spindle box. Through the Y-axis drive device, the milling main spindle box will move upwards and downwards along the vertical direction. On the right side of the column there is one straight-line coding ruler, which is used to feed back the milling main axis center s actual position along the Y-axis direction. At the upper and lower ends of the left side there is respectively a stroke limit switch. At the upper and lower ends of the column there is respectively an iron block that is used to prevent the milling main spindle box from going beyond the stroke along the vertical direction. On the top of the column there is the installation basis for Y-axis drive device. 5.4 Y-axis Drive Device Y-axis drive device is used to make the milling main spindle box move upwards and downwards along the vertical direction, and its principle is as follows: the motor drives a pair of gears to make the lead screw s nut rotate (X and Z-axis drive mean the lead screw s rotary motion), which will accordingly drive the lead screw move upwards and downwards. At the end of the lead screw a flange is used to connect with the milling main spindle box s body. Due to this, lead screw s vertical motion will drive the milling main spindle box s upwards and downwards motion. The milling main spindle box and its parts are heavy (about 1200kg). If the lead screw assumes all loads, the ball bearing lead screw s load will be relatively high. Moreover, the lead screw will be subject to wearing during the application process. In view of this, two balancing cylinders are installed respectively at the upper part of the column and along the Y-axis s ball bearing lead screw center line. As a result, most of the milling main spindle box and its parts weight will be balanced by the balancing cylinder s oil pressure. That will greatly alleviate the load by which the Y-axis drive device drives the milling main spindle box to move upwards and downwards, which will help not only mitigate the lead screw s wearing, but also improve the moving precision. 5.5 Milling Main Spindle Box (Cutter Box) Main axis motor, through two pairs of gears, drives the main axis s rotation. Meanwhile, the motor s rotating speed hits RPM, and subjects to the computer s control. Operators shall select appropriate rotating speed according to the machined object and dimension. In the milling main spindle box, both the bearing and gear pair adopt the anti-wearing hydraulic oil from the hydraulic station for lubrication, and these oil can automatically flow back into the hydraulic oil tank. Head of the main axis is a standard main axis end of the spiral bevel gear milling machine cutter. In addition, the positioning code with conical degree of 1:24 has a diameter of φ at its big end, and it is used for installing inch facing cutter. When the 12~16 inch facing cutter shall be installed, end of the main axis shall be equipped with the cutter holder, whose size at the big end is φ , with conical degree of 1: 24. When the machine will process the Oerlikon gear, the end of the machine s main axis shall be equipped with Oerlikon cutter, and then the cutter holder II shall be installed at the end of the main axis. Such a holder s size at the big end is φ131, with conical degree of 1: 4. On both sides of the box body there are slide blocks for straight-line rolling guide rail pair. When the Y-axis drive device s motor rotates, the TOS-013-US

10 gear pair will drive the screw assembly s nut to rotate. That will make the lead screw and the entire milling main spindle box to drive vertically along the straight-line guide rail pair. On the left side of the milling main spindle box there is a stroke limit switch that moves vertically. Fixed ruler of the Y-axis straight-line coding ruler is installed on the column, whereas the sliding ruler is fixed on the milling main spindle box s body to reflect the moving milling main axis center s position along the vertical direction. 5.6 Z-axis Slipway Z-axis slipway s drive mode is the same as the X slipway s drive mode. Z-axis slipway s drive case is installed at the right end of the machine body, and the straight-line guide rail pair s guide rail is installed on the body, but the slide block is installed on the slipway. In addition, the machine s rotary table is directly installed on the Z-axis slipway, whereas the work piece box is installed on the rotary table. When Z-axis slipway moves along the left or right direction, work piece s relative motion towards facing cutter along the Z-axis direction will be realized. On one side of the Z-axis slipway s frontal face there is one straight-line grating scale, which can feed back work piece s coordinate position relative to facing cutter along the Z-axis direction. On the other side of the slipway there is stroke limit switch that limits the slipway motion and electric switch that marks the reference point. In addition, the mechanical limit device is additionally installed to prevent the slipway from going beyond the stroke. It is worth pointing out that the slipway is installed on the straight-line rolling guide rail and equipped with front and rear guide rail protection devices. Since the Z-axis slipway s guide rail stays at the horizontal installation location, particularly its frontal end is located underneath the machining zone, it is necessary to adopt precise protective actions. 5.7 Rotary Table Rotary table is installed on the Z-axis slipway s platform, and the rotary table s center of rotation is the center of B-axis and the center of the machine. In addition, the turning angle, around which axis (B-axis) turns on the rotary table s bracket, is the B-axis s rotary angle. When the work piece axis s center and the milling head main axis s central line form an angle of 90, the rotary table stays at the 0 position. When the rotary table rotates along the clockwise direction towards the work piece axis s central line and becomes parallel with the milling head main axis s central line, the rotary table stays at the position of 90. The motor, which is equipped with planet gear deceleration unit, drives the small friction pulley s self rotation through the coupler. Oil pressure in the oil cylinder makes the big and small friction pulleys contact with one another closely, in addition to enabling the small friction pulley to exert large positive pressure on the big friction pulley (the positive pressure can be adjusted through the oil pressure). Due to the positive pressure, there will be relative rolling without sliding between the big pulley and the small pulley. And then the small friction pulley, together with the rotary table and its parts like the work piece box, will move back and forth around the rotary table s axis center (center of the B-axis). As a matter of fact, only when the thrust deriving from the small pulley s positive pressure on the big pulley is larger than the rotary table and its parts resistance, can the sliding be eliminated and can the pure rolling be generated. Since the positive pressure s increase will exert negative influence on the machine precision and the moving resistance originates from the rotary table and its parts weight, weight reduction and transfer of these parts will help realize such an objective. To achieve this objective, the machine s rotary table is equipped with three unload cylinders (See the figure), which can ensure the even force distribution on the three unload pulleys, and alleviate the friction and resistance during the rotary motion period. During the rotary table s rotating process, two stroke limit switches are respectively installed at two limit positions. To accurately feed back the rotary table s correct angular coordinate during the linkage, the RON285 angle encoder is installed on the top of the rotary central axis. TOS-013-US

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14 6. Specification of machine THB 600 CNC 6.1 Basic machine Code Pcs Item THB 600 CNC 1 Gear bevel hobbing machine THB 600 CNC Machine CNC system and Software: CNC system SIEMENS 840 D sl, 6 axes Display 15 TFT Servo drive System SIEMENS Digital AC Motor Electrical Hand Wheel Siemens System Form a Complete Set Electricity 380 V ±10% Electrical Hand Wheel 6.2. Standard equipment Pos. Qty Item 2. 2 Documentation, instruction manual in English Control system Siemens SINUMERIC 840 D sl, drives Siemens, SW, linear and rotary scanners, Automatic centralize lubrication system and hydraulic system. Cooling system, Coolant Filtration System, Automatic chip conveyor Air-conditioned integrated electrical cabinet with net cable, CNC numerical control equipment and integrated PLC. Machine control panel with display and electrical hand wheel. Switch for workpieces clamp and unclamp. Germany REXROTH or Japan THK rolling guide and NSK ball screw, linear axes and revolving spindle adopt Germany Heidenhain high resolution linear and rotary encoders SIEMENS spindle motor and servo AC motors Spiral bevel gear milling machining software Electrical report (СЕ) Set of operation instruments Protocol of geometric accuracy days operating training (technology) and maintenance (mechanical + electronical) at producer factory Warranty 12 months Machine coulour RAL shade according to customer wish TOS-013-US

15 6.3. Optional equipment Spiral bevel gear hobbing machine THB 600 CNC Pos Code No. of pcs Subject 19. TKPN 18 1 Device for the assembly and control of tool heads TKPN STCA 1 Software for calculating design transfers Hardness calculation and calculation of fatigue transmissions Software for moving deviations TCA analysis - Spiral bevel gear design and analysis of machining, spiral conic and semi-synthetic transmission software for the design of the processing and analysis of the contact tooth program (TCA). LTCA analysis Software Opposition testing Software 21. CHT 1set Cutter head Hardac (5 Pcs.) for bevel gears type Gleason with parameters according to special request on requirement of customer (example) TOS-013-US

16 Dialog system TOS-013-US

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